1998 SSANGYONG MUSSO transmission

AUTOMATIC TRANSMISSION 5A-107
C3 Clutch and Reverse Sun Gear Assembly
To assemble the C3 clutch and reverse sun gear assembly
(refer to figure 8.28), proceed as follows.
1. Check the orifices in the cylinder are clear of obstructions.
2. Check the C3 cylinder bush outside diameter and the
centre support inside diameter are in good condition and
not damaged. Coat the sealing rings with automatic
transmission fluid and fit into the C3 cylinder grooves.
3. Check the reverse sun gear splines, grooves and thrust
face for condition. Coat the ‘O’ ring with automatic
transmission fluid and fit it to the groove of the reverse
sun gear.
4. Install the reverse sun gear in the C3 cylinder, ensuring
that the ‘O’ ring compression is adequate but not
excessive.
Notice
‘O’ rings must not be twisted in the grooves.
5. Coat the C3 piston ‘O’ rings with automatic transmission
fluid and fat the small ‘O’ ring onto the inner ring and the
large ‘O’ ring onto the outer ring of the C3 piston.
6. Check that the bleed orifices of the piston are clean and
clear of obstructions.
7. Install the C3 piston in the cylinder until the outside
diameter of the piston enters the inside diameter of the
cylinder.
Notice
Take care not to cut the ‘O’ ring.
8. Assemble the spring and spring retainer on the piston.
Using tool No. 0555-331899 compress the spring
sufficiently to enable the installation of the retaining circlip,
ensuring that the circlip is firmly seated in the groove, and
remove the tool.
9. Fit the C3 wave plate to the C3 piston face, ensuring that
one crest of the wave plate of the C3 piston face is aligned
over one of the piston orifices.
10. Assemble the clutch plates and discs into the cylinder in
the following sequence :
lSteel plate
lFriction disc
lSteel plate
lSteel plate - 0574-000001, 0574-000003,
0574-000004,0574-000005,0574-000020,
0574-000021, or friction disc -0574-000002
lSteel plate (selective)
lFriction disc
lSteel plate (selective)
lFriction disc
11. Align and fit the pressure plate with the counterbore facing
away from the clutch plates.Figure 8.28 - C3 Clutch and Reverse Sun Gear

5A-108 AUTOMATIC TRANSMISSION
12. Install the circlip.
13. Check the C3 clutch clearance (refer to figure 8.29) using
special tool No.0555-331900 in the following manner
(weight only).
a. Place the weight on the pressure plate and measure
the distance from the end of the cylinder to the top of
the pressure plate.
b. Record this figure.
c. Remove the weight.
d. Lift the pressure plate up against the circlip and
measure the distance from the end of
the cylinder to the top of the pressure plate.
e. Record this figure.
f. Subtract the second reading from the first reading to
obtain the clutch pack clearance.
Notice
With the clutch pack supporting a weight of 2 kg, the
clearance between the snap ring and the top of the
pressure plate is to be between 1.20-1.45 mm.
14. If new friction plates are being fitted, remove the clutch
pack and soak the friction elements in automatic
transmission fluid for a minimum of five minutes prior to
reassembly.
Notice
The clutch pack clearance must be taken before the
elements are soaked in automatic transmission fluid.Figure 8.29 - Typical C3 Clutch Assembly
Clearance

AUTOMATIC TRANSMISSION 5A-109
Forward Sun Gear and C3 Clutch Pack Assembly
To assemble the forward sun gear and C3 clutch pack assembly
(Refer to figure 8.30), proceed as follows:
1. Fit the No. 7 needle thrust bearing assembly over the forward
sun gear, ensuring that the thrust washer is between the
bearing and the sun gear.
2. Lubricate the thrust plate with petroleum jelly and fit the
thrust plate onto the reverse sun gear.
Refer to figure 8.33.
3. Align and fit the C3 clutch assembly over the forward sun
gear.
4. Lubricate the No. 6 needle thrust bearing with petroleum
jelly and fit it to the thrust plate. Ensure the lugs on the
outside diameter of the bearing fit in the thrust plate
counterbore.
Refer to figure 8.19.
5. Align and fit the plastic thrust washer to the thrust plate with
petroleum jelly.
Refer to to figures 8.19.
6. Install the assembly over the forward sun gear shaft against
the No.6 thrust bearing.
Refer to figure 8.19.
7. Place the assembly to one side.
Figure 8.30 - Typical forward Sun Gear add C3 Clutch Assembly

5A-110 AUTOMATIC TRANSMISSION
C1 Clutch Overdrive Shaft and Input Shaft
Assembly
Notice
1. Ensure that the snap rings are fitted correctly.
2. Check pistons for cracks, especially the C1 piston.
3. Do not mix clutch piston return springs.
4. If the C1/C2 clutch packs separate from the C3 clutch pack,
make sure the No. 6 bearing doesn’t drop out of the bearing
retainer.
To assemble the C1 clutch overdrive shaft and input shaft
assembly, proceed as follows:
1. Check the overdrive shaft grooves for any defect.
2. Coat the sealing rings, large and small, with petroleum jelly
and fit them to the overdrive shaft. The sealing rings may
be held in place with a small amount of petroleum jelly.
3. Assemble the clutch plate and disc into the cylinder in the
following sequence:
lsteel plate
lfriction disc
lsteel plate
lfriction disc
lsteel plate
lsteel plate - 0574-GOOGOl, 0574-000003,
0574-000004, 0574-000005, 0574-000020,
0574-000021, or friction disc -0574-000002
lsteel plate (selective)
lfriction disc
lsteel plate (selective)
lfriction disc
4. Check the clutch pack clearance using special tool No.0555-
331900. Refer to figure 8.31.
Use selective plates to achieve the correct specification.
Notice
The clutch pack supporting a 2 kg weight, the dimension
from the input shaft locating stop to the friction disc must
be 0.70-0.90 mm.
5. If new friction plates are being fitted, remove the clutch pack
and soak the friction elements in automatic transmission
fluid for a minimum of five minutes prior to assembly.
Notice
The clutch pack clearance must be taken before
elements are soaked in automatic transmission fluid.
6. Check the fit of the C1 clutch hub on the overdrive shaft. If
it is loose, the hub and shaft assembly must be replaced.Figure 8.31 - Typical C1 Clutch Assembly
Clearance

AUTOMATIC TRANSMISSION 5A-111
7. Coat the small nylon thrust spacer with petroleum jelly and
install it over the overdrive shaft. Refer to figure 8.19.
8. Carefully fit the overdrive shaft into the C1 cylinder so as
not to damage the sealing ring.
9. Fit the small bronze C1 hub thrust washer in place with
petroleum jelly. Refer to figure 8.19.
10. Check the input shaft for any defect. Fit the input shaft
into the cylinder and secure it with the circlip, ensuring
that the circlip is completely seated in the groove.
11. Coat the sealing rings with petroleum jelly and fit onto the
input shaft.
12. Assemble the C1/C2/C4 clutch assembly to the C3 clutch
and sun gear assembly. Refer to figures 8.32 and 8.33.
13. Install this assembly in the transmission case.

5A-112 AUTOMATIC TRANSMISSION
Pump Cover and Converter Support
Notice
1. Do not wash the nose of solenoids in solvent.
2. Ensure that the correct ‘O’ ring is fitted for the application.
3. Do not mix up the low first blow-off and the torque converter
blow-off ball springs.
4. Be careful not to damage the needle bearings on the
assembly. Avoid any axial impact loads during assembly.
5. Check the transmission end float. This will help to detect
any missing parts or incorrect assembly.
Notice
Figure 8.35 shows the orientation of the cross- sections for
figures 8.36 to 8.42.
To assemble the pump cover and converter support
(refer to figures 8.34 and 8.35), proceed as follows.
1. Check the pump body for any damage, chips or irregularity.
Check that the bush is firmly staked in the drive gear.
2. Install the seal flush with the front face of the pump body.
3. Lubricate the pump bush, and the drive and driven gears,
with automatic transmission fluid.
4. Install the pump driven gear and the pump drive gear into
the pump body.
5. Using a straight edge and thickness gauge, check that the
clearance between pump face and gears is 0.04 - 0.018
mm.
6. Lubricate the pump body ‘O’ ring with automatic transmission
fluid and fit it to the pump body. Put the pump body to one
side.
7. Ensure that the pump cover cavities, ports and holes are
clean and free of any obstruction.
8. Lubricate all loose parts with automatic transmission fluid
prior to assembly.Figure 8.34 - Pump, Cover and Converter
Support
Figure 8.35 - Pump Cover Assembly

AUTOMATIC TRANSMISSION 5A-113
9. Assemble the primary regulator valve and plunger (refer
to figure 8.36) to the pump cover, ensuring that the
regulator valve slides freely, then fit the regulator valve
plug and ‘O’ ring.
10. Install the retaining pin.
11. Install the converter clutch regulator valve (refer to figure
8.37), plug, and ‘O’ ring.
Figure 8.36 - Primary Regulator Valve
Figure 8.37 - Converter Clutch Regulator Valve

5A-114 AUTOMATIC TRANSMISSION
13. Install the converter clutch control valve (refer to figure
8.38), spring, plug, and ‘O’ ring.
14. Install the retaining pin. Refer to figure 8.39.
Figure 8.39 - Valve Retaining Plugs and Pins
Figure 8.38 - Converter Clutch Control Valve 12. Install the retaining pin. Refer to figure 8.39.